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Control of Gaseous Emissions Student Manual

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Control of Gaseous Emissions Student Manual Air Pollution Training Institute (APTI) United States MD 17 January 2000 Environmental Protection Environmental Research Center Agency Research Triangle Park, NC 27711 Air Control of Gaseous Emissions Student Manual APTI Course 415 Third Edition Author John R. Richards, Ph.D., P.E. Air Control Techniques, P.C. Developed by ICES Ltd. EPA Contract No. 68D99022 Control of Gaseous Emissions ICES Ltd. The Multimedia Group Customized Multimedia Information and Training Solutions Acknowledgments The author acknowledges the contributions of Dr. James A. Jahnke and Dave Beachler, who authored the first edition of Control of Particulate Emissions in 1981 under contract to Northrop Services Inc. (EPA 450/2-80-068). In 1995, the second edition of this text was published, authored by Dr. John R. Richards, P.E., under contract to North Carolina State University (funded by EPA grant). ii Control of Gaseous Emissions Control of Gaseous Emissions Student Manual APTI Course 415 Third Edition Author John R. Richards, Ph.D., P.E. Air Control Techniques, P.C. Developed by ICES Ltd. EPA Contract No. 68D99022 iii Control of Gaseous Emissions Acknowledgments The author acknowledges the contributions of Gerald Joseph, P.E. and Dave Beachler, who authored the first edition of Control of Gaseous Emissions in 1981 under contract to Northrop Services Inc. (EPA 450/2-81-005). In 1995, the second edition of this text was published, authored by Dr. John R. Richards, P.E., under contract to North Carolina State University (funded by EPA grant). iv Control of Gaseous Emissions TABLE OF CONTENTS Chapter 1 Introduction 1.1 Introduction to Gaseous Contaminants 1-1 1.1.1 Sulfur Dioxide and Sulfuric Acid Vapor 1-2 1.1.2 Nitrogen Oxide and Nitrogen Dioxide 1-2 1.1.3 Carbon Monoxide and Other Partially Oxidized Organic Compounds 1-3 1.1.4 Volatile Organic Compounds or Other Organic Compounds 1-3 1.1.5 Hydrogen Chloride and Hydrogen Fluoride 1-5 1.1.6 Hydrogen Sulfide and Other Total Reduced Sulfur Compounds 1-6 1.1.7 Ammonia 1-6 1.1.8 Ozone and Other Photochemical Oxidants 1-6 1.2 Sources of Gaseous Contaminants 1-8 1.3 Gaseous Contaminant Regulations 1-10 Review Exercises 1-12 Review Answers 1-14 References 1-15 Chapter 2 Control Techniques for Gaseous Contaminants 2.1 Gas Stream Characteristics 2-1 2.1.1 Important Gas Stream Properties 2-1 2.1.2 Particulate Matter 2-1 2.1.3 Explosive Limit Concentrations 2-2 Problem 2-1 2-4 Problem 2-2 2-5 2.2 Gaseous Contaminant Control Techniques 2-6 2.2.1 Adsorption 2-7 2.2.2 Absorption and Biofiltration 2-8 2.2.3 Oxidation 2-10 2.2.4 Reduction Systems 2-12 2.2.5 Condensation 2-13 2.2.6 Summary of Control Techniques 2-14 Review Exercises 2-16 Review Answers 2-18 References 2-19 Chapter 3 Air Pollution Control Systems 3.1 Flowcharts 3-1 3.1.1 Flowchart Symbols 3-2 3.1.2 Diagrams 3-6 Problem 3-1 3-8 Problem 3-2 3-12 v Control of Gaseous Emissions 3.2 Gas Pressure, Gas Temperature, and Gas Flow Rate 3-15 Problem 3-3 3-16 Problem 3-4 3-17 Problem 3-5 3-19 Problem 3-6 3-20 3.3 Hoods 3-20 Problem 3-7 3-22 Problem 3-8 3-23 3.3.1 Hood Operating Principles 3-23 Problem 3-9 3-25 3.3.2 Monitoring Hood Capture Effectiveness 3-27 Problem 3-10 3-30 Problem 3-11 3-33 3.4 Fans 3-34 3.4.1 Types of Fans and Fan Components 3-34 3.4.2 Centrifugal Fan Operating Principles 3-37 Problem 3-12 3-44 3.4.3 Effect of Gas Temperature and Density on Centrifugal Fans 3-46 Problem 3-13 3-47 Review Exercises 3-50 Review Answers 3-54 References 3-60 Chapter 4 Adsorption 4.1 Types and Components of Adsorption Systems 4-1 4.1.1 Adsorbents 4-1 4.1.2 Characteristics of Adsorbents 4-4 4.1.3 Adsorption Systems 4-5 4.2 Operating Principles 4-13 4.2.1 Adsorption Steps 4-13 4.2.2 Adsorption Forces 4-14 4.2.3 Adsorption-Capacity Relationships 4-16 Problem 4-1 4-17 4.3 Capability and Sizing 4-19 4.3.1 Applicability 4-19 4.3.2 Adsorption Capacity 4-21 Problem 4-2 4-21 Problem 4-3 4-23 4.3.3 Adsorbent Regeneration Methods 4-27 Problem 4-4 4-28 4.3.4 Instrumentation 4-30 Review Exercises 4-35 Review Answers 4-39 References 4-43 vi Control of Gaseous Emissions Chapter 5 Absorption 5.1 Types and Components of Absorbers 5-2 5.1.1 Types of Absorbers 5-2 5.1.2 Components Common to Most Absorption Systems 5-13 5.2 Operating Principles 5-16 5.2.1 Mechanisms of Absorption 5-16 Problem 5-1 5-19 5.2.2 Contaminant Reactions 5-21 5.2.3 Biofiltration 5-22 5.3 Capability and Sizing 5-22 5.3.1 Gaseous Pollutant Removal Capability 5-22 5.3.2 Absorber Sizing 5-23 Problem 5-2 5-29 5.3.3 Packed Tower Absorber Diameter and Height 5-31 Problem 5-3 5-34 Problem 5-4 5-39 5.3.4 Tray Tower Absorber Diameter and Height 5-40 Problem 5-5 5-42 Problem 5-6 5-44 5.3.5 Mist Eliminator Evaluation 5-45 5.3.6 Alkali Requirements 5-45 Problem 5-7 5-46 5.3.7 Instrumentation – Standard Absorbers 5-46 5.3.8 Instrumentation – Biofiltration Systems 5-50 Review Questions 5-52 Review Answers 5-55 References 5-58 Chapter 6 Oxidation 6.1 Types and Components of Oxidizer Systems 6-2 6.1.1 High Temperature, Gas Phase Oxidation Systems 6-2 6.1.2 Catalytic Oxidation Systems 6-9 6.2 Operating Principles 6-13 6.2.1 High Temperature, Gas Phase Oxidation Systems 6-13 Problem 6-1 6-16 Problem 6-2 6-18 6.2.2 Catalytic Oxidation Systems 6-19 6.3 Capability and Sizing 6-20 6.3.1 Destruction Efficiency 6-20 Problem 6-3 6-25 6.3.3 Acid Gas Emissions 6-27 Problem 6-4 6-27 6.3.4 Instrumentation – High Temperature, Gas Phase Oxidation Systems 6-29 6.3.5 Instrumentation – Catalytic Oxidation Systems 6-31 Review Exercises 6-33 vii Control of Gaseous Emissions Review Answers 6-36 References 6-39 Chapter 7 Condensation 7.1 Types of Systems 7-1 7.1.1 Conventional Systems 7-1 7.1.2 Refrigeration Systems 7-5 7.1.3 Cryogenic Systems 7-6 7.2 Operating Principles 7-8 Problem 7-1 7-9 7.3 Capability and Sizing 7-10 7.3.1 Efficiency 7-10 Problem 7-2 7-10 7.3.2 Sizing of Conventional Condensers 7-11 Problem 7-3 7-16 Review Exercises 7-19 Review Answers 7-21 References 7-23 Chapter 8 Nitrogen Oxides Control 8.1 Introduction to NOx Formation and Emission Sources 8-1 8.1.1 Formation of Nitrogen Oxides in Stationary Sources 8-1 8.1.2 Calculating Nitrogen Oxides Emissions 8-2 Problem 8-1 8-2 8.1.3 NOx Emission Sources 8-3 8.2 Types and Components of NOx Control Systems 8-10 8.2.1 Boiler Combustion Modifications 8-10 Problem 8-2 8-10 Problem 8-3 8-12 8.2.2 Gas Turbine Combustion Modifications 8-19 8.2.3 Fuel Switching 8-20 8.2.4 Flue Gas Treatment 8-21 8.3 Operating Principles of Flue Gas Treatment Systems 8-23 8.3.1 Selective Non-catalytic Reduction 8-23 8.3.2 Selective Catalytic Reduction (SCR) 8-26 8.4 Capability and Sizing of NOx Control Systems 8-27 8.4.1 Nitrogen Oxides Emission Reduction Efficiency 8-27 8.4.2 Ammonia or Urea Feed Requirements 8-28 Problem 8-4 8-28 8.4.3 NOx Continuous Emission Monitoring 8-29 8.4.4 Carbon Monoxide Continuous Emission Monitors 8-30 8.4.5 Oxygen Concentration Monitors 8-30 8.4.6 Instrumentation 8-31 Review Exercises 8-32 Review Answers 8-35 References 8-37 viii Control of Gaseous Emissions Chapter 9 Sulfur Oxides Control 9.1 Types and Components of Sulfur Oxides Control Systems 9-1 9.1.1 Sulfur Oxides Formation Mechanisms 9-1 Problem 9-1 9-2 9.1.2 Low Sulfur Fuel Firing 9-3 Problem 9-2 9-4 9.1.3 Flue Gas Desulfurization 9-5 9.1.4 Dry Scrubbing 9-9 9.1.5 Fluidized Bed Combustion 9-12 9.1.6 Fuel Treatment 9-12 9.2 Operating Principles 9-14 9.2.1 Nonregenerative and Regenerative Wet Scrubbers 9-14 9.2.2. Dual Alkali Scrubbing 9-16 9.2.3 Magnesium Oxide Scrubbing 9-17 9.2.4 Wellman-Lord 9-17 9.2.5 Dry Scrubbing 9-18 9.3 Sulfur Oxides Control Systems Capability and Sizing 9-19 9.3.1 Sulfur Dioxide Removal Efficiency 9-19 9.3.2 Fuel Sulfur Sampling Systems 9-20 9.3.3 Alkali Requirements 9-21 Problem 9-3 9-22 9.3.4 SO2 Continuous Emission Monitoring 9-23 9.3.5 Instrumentation 9-24 Review Exercises 9-26 Review Answers 9-28 References 9-30 ix Control of Gaseous Emissions LIST OF FIGURES Figure 1-1.
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